ition

conditoring
mon ViB
vibration

Successful Solution
to the Challenge of Low RPM
Tim Sundström

Bearing Monitoring
Above: An SPM HD Spectrum measured on October 29 at 10.84
RPM. The outer race signal is clear, with several harmonics. The
Above: An SPM HD trend spanning between mid-June, 2010 to
amplitude has increased 20 times indicating more severe outer
end of November, 2010, showing 624 readings taken approxi- race damage.
mately 6 hours apart. The graph shows the primary parameter
produced by the SPM HD method: the strongest impact found
during the measuring time. The Y scale is logarithmic.
The difference between the lowest and the highest value in

U
Low RPM applications have sing the newly developed SPM High Definition
(SPM HD) method, we have been able to reveal
been notoriously difficult to never-before-seen details at very low RPMs (< 5
monitor with traditional RPM). The SPM HD method is based on the fact that in
the interface between the rolling elements and the race-
vibration-based techniques. ways in an antifriction bearing, elastic, very short dura-
The energy involved at RPMs tion waves are generated. Damage—for example, a spall
below 50 is very low, making it or a crack—will generate a high number of elastic waves
due to the metal-to-metal collision when the rolling ele-
a difficult task to extract mean- ments pass the damaged area. Using a transducer sen-
ingful information from the sitive to these elastic waves makes it possible to record
and quantify the waves. The transducers should be per-
measured signal. manently installed, either mounted in drilled, counter-
sunk mounting holes on the bearing housings, or glued
onto the surface. For best results, the transducers should
be mounted close to the bearing load zone.
the trend graph is about 30 dB (30 times on a linear scale). The
drop in the value from 40 dB to 8 dB is after bearing replacement.
A moving average filter has been applied with 10 average values.
This explains why the values seem to decrease slowly after the
replacement. Note the typical pattern of increasing values fol-
lowed by a period of decreasing values. This behavior is caused
by fresh spalling followed by a period of mechanical softening of
the sharp edges around the spall. When the rolling elements col-
lide with the sharp edges of the spall, strong elastic waves will be
generated at the point of collision. After some period of time (a Above: On November 6, 2010, a new frequency component be-
couple of weeks in this application) the sharp edges wear down
comes visible in the spectrum, directly corresponding to the
BPFI. The outer race frequency is still there, and the typical 1X
and the metal-to-metal collisions become less strong, hence modulation of the inner race signal is obvious. This measure-
decreasing the strength of the elastic waves. The next spall will ment is at 10.85 RPM. This behavior of an initial steady increase of
then generate a similar pattern. the outer race signal, followed by a distinct inner race signal, has
been found in several places on this application.

At Holmen Hallsta paper mill in Sweden, a field

test on four twin wire presses (used in the pulp
industry for dewatering purposes) has been running
for nineteen months. During this period, thirteen
bearing faults have been successfully identified.
There are examples from the test period where the
pre-warning time has been over fourteen months
between the first damage indication and replace-
ment of the bearing. A more typical pre-warning
time is about six months. Typical RPM ranges from
7 to 16. The system is taking measurements every 6 hours and a typical Above: An SPM HD Spectrum taken in a very early stage of the
measuring time at this RPM range is about 10 minutes.
bearing deterioration process. The Y scale is linear and 5 harmon-
Using a real case example from the twin wire press application, Figure 1 is an account of the different
ics to the BPFO line can be seen. The reading was taken on Au-
stages of the bearing deterioration process, detected with the SPM HD method.
gust 23, 2010 and RPM on this occasion was 9.39. Above: An SPM HD Time signal with extraordinary sharpness.
56 feb/march11 feb/march11 57
 The reading was taken on November 12, 2010 and clearly
shows an inner race and an outer race signal in combination. The
RPM is 10.84. Note the inner race modulation where the distance
EMPLOYMENT OPPORTUNITY between the “bursts” is exactly 1 revolution. Also note the smaller
signals from the outer race.
VIBRATION ANALYST/INSTRUCTOR
The typical time signal pattern from an inner race damage
as seen in this picture is explained by studying a bearing load
zone. When the inner race damage enters the load zone, it will
collide with the rolling elements. In the middle of the load zone,
the forces are strongest, hence producing the strongest impacts.
When the damaged area of the inner race leaves the load zone,
the impacts will decrease again.
Immediate opening in Charlotte, NC (Relocation required) with The fact that the strongest impacts are not constant in ampli-
Technical Associates for an experienced person to do Vibration tude is an interesting observation. Studying the picture above,
Diagnostics, implement PdM programs and teach Vibration it is clearly seen that the strongest impact from each “burst” ex-
Analysis Seminars (Concentrating on Predictive Maintenance). US
Citizenship Required.
hibits a cyclic change. The explanation can be found in bearing
geometry. Sometimes, the damaged area, the maximum load
The individual should have extensive Vibration Analysis experience tional clarity. Even on low RPM applications, spectrums and time
on rotating equipment using FFT Analyzers. Good communication zone force, and a rolling element coincide, producing a strong
skills are a necessity, along with the capability to instruct seminars collision. Sometimes they will not coincide, resulting in a lower
for 15 to 25 people. amplitude impact.
Opportunity to work with leaders in the Vibration Industry for the
past 32 years. For confidential consideration, please email resume to actual bearing replacement.
Ron Kretel at rkretel@technicalassociates.net
As mentioned earlier, this is but one example from the twin
wire press application. The other twelve cases are similar to this
one. In most of the cases, the increasing/decreasing trends are
more pronounced. Based on the twin wire press application as
well as other low RPM applications, our experience is that due
to the increasing/decreasing trends, measuring with handheld
equipment is not advisable for low RPM applications. There is an
obvious risk that the measurement was taken during a period
where the edges of a possible spall are “soft,” and therefore pro- Disassembled
duce low amplitude impacts. Unless measured very frequently bearing
with handheld equipment, we strongly recommend continuous with
spallings.
measurements using online equipment.
Conclusions Tim Sundström, born 1964 in Sweden, has a M.Sc.
degree in Applied Physics and Electrical Engineering
The SPM HD method enables measuring results with excep- from Linköping University, Sweden. For over twenty
years, he has been specializing in electronics develop-
ment and has held managerial positions in the field
signals are crisp. In field tests running for more than nineteen since 1992. In 2001, he joined SPM Instrument as head
months, we have been successful in the identification of bearing of Research and Development, where he has been deeply
damages, typically with six months pre-warning time before the involved in SPM HD development and field evaluations.
Visit www.spminstrument.com

Technical Associates
347 N. Caswell Road, Charlotte, NC 28204
Phone: (704) 333-9011 • Fax: (704) 333-1728

APPLIED MODAL & ODS ANALYSIS SEMINAR

Technical Associates of Charlotte, P.C.
This 4.5 Day (36 hrs.) course provides a basic
understanding on how to use Experimental Modal
Analysis (EMA) and Operating Deflection Shape
Analysis (ODS). The focus of this entire class is
on Applying these powerful diagnostic tools on
Above: SPM HD Time signal immediately before bearing
real-world machinery and structures.
replacement.
Modal and Operating Deflection Shape Theory:
• How to Construct Meaningful Computer Models
• Choosing Required Numbers of Points & Directions
• Recommended Measurement Setups
• How to Properly Perform ODS & Modal Measurements
• How to Accurately Interpret Computer Model Animations
• How to Confirm What Component is Resonant
• How to Develop Optimum Corrective Actions
• Presentation of Numerous Demos & Class Exercises
• Presentation of Real-World ODS & Modal Case Studies
Hands-On ME’scopeVES Software Training
(Using Our Own Updated “ME’scopeVES Handbook”)
Covers the following ME’scopeVES topics:
• Creating a Structural or Machine Computer Model
• Importing Data From Your Acquisition Instrument
• Modal Analysis Curve Fitting
• Animating & Accurately Interpreting Modal & ODS Computer Models
• Work with Actual Modal/ODS Data
• Structural Dynamics Modification Capability (SDM)
Above: SPM HD Time signal immediately after bearing
replacement.
4 Hour Hands-On Workshop Using ME’scopeVES on Final Class Day
March 28 – April 1, 2011; Charlotte, NC - $1995
Contact Cheryle Benton at cbenton@technicalassociates.net In the two figures above, note the amplitude compared with
Tel: (704) 333-9011 the picture from before bearing replacement. The amplitude dif-
ference between a damaged bearing and a new one is obvious.

58 feb/march11 feb/march11 59